Coated film for insert mold decoration, methods for using the same, and articles made thereby

Abstract

In an embodiment, a coated thermoplastic film, comprises a polymeric film substrate; and a coating formed from a coating composition comprising a urethane acrylate having a functionality of 2.0 to 6.0 acrylate functional groups; an acrylate monomer having a functional group; and an epoxy acrylate oligomer; and an additive comprising at least one of a silicone based additive, palmitic acid, and combinations comprising at least one of the foregoing. In an embodiment, a method of molding an article comprises decorating and forming the coated thermoplastic film to form a shaped film, and placing the shaped film into a mold, and injecting a resin into the mold cavity space behind the shaped film, wherein the shaped film and the injection molded resin form a single molded part.

What is claimed is: 
     
       1. A coated thermoplastic film, comprising:
 a polymeric film substrate; and 
 a coating formed from a coating composition comprising
 a urethane acrylate having a functionality of 2.0 to 6.0 acrylate functional groups; 
 an acrylate monomer having a functional group; 
 an epoxy acrylate oligomer; and 
 
 an additive comprising at least one of a silicone based additive, palmitic acid, and combinations comprising at least one of the foregoing; 
 wherein the epoxy acrylate oligomer has one or more of an elongation percent at break of greater than or equal to 35%; a viscosity of less than or equal to 500 centipoise at 25° C.; a tensile strength of greater than or equal to 5 MegaPascals; a functionality of 1 to 6 functional groups; and a glass transition temperature of less than or equal to 25° C. 
 
     
     
       2. The coated thermoplastic film of  claim 1 , wherein the coating composition comprises about 30 wt. % to about 70 wt. % urethane acrylate, about 20 wt. % to about 40 wt. % acrylate monomer, about 10 wt. % to about 40 wt. % of the epoxy acrylate oligomer, and about 0.1 wt. % to about 5 wt. % of the additive. 
     
     
       3. The coated thermoplastic film of  claim 1 , wherein the additive comprises polydimethysiloxane acrylate copolymer, polyether polydimethysiloxane, polyalkyleneoxide modified polydimethylsiloxane copolymer, palmitic acid, or a combination comprising at least one of the foregoing. 
     
     
       4. The coated thermoplastic film of  claim 1 , wherein the additive comprises palmitic acid and polyalkyleneoxide modified polydimethylsiloxane copolymer. 
     
     
       5. The coated thermoplastic film of  claim 1 , wherein the additive comprises about 0.1 wt. % to about 1.0 wt. % palmitic acid and about 0.1 wt. % to about 1.0 wt. % polyalkyleneoxide modified polydimethylsiloxane copolymer. 
     
     
       6. The coated thermoplastic film of  claim 1 , wherein the polymeric film substrate comprises polycarbonate. 
     
     
       7. The coated thermoplastic film of  claim 6 , wherein the polycarbonate film substrate comprises a co-extruded multilayer film comprising
 a first layer comprising a blend of polycarbonate comprising repeat units of dimethyl bisphenol cyclohexane monomer and a polycarbonate comprising repeat units of bisphenol A; and 
 a second layer comprising a polycarbonate comprising repeat units of bisphenol A without polycarbonate comprising repeat units of dimethyl bisphenol cyclohexane monomer. 
 
     
     
       8. The coated thermoplastic film of  claim 1 , wherein the silicone based additive is present in an amount of 0.3 to 2.5 wt. %. 
     
     
       9. The coated thermoplastic film of  claim 1 , wherein the silicone based additive is present in an amount of 0.4 to 1 wt. %. 
     
     
       10. The coated thermoplastic film of  claim 1 , wherein the silicone based additive is present in an amount of 0.1 to 3 wt. %. 
     
     
       11. A molded article, comprising:
 the coated thermoplastic film of  claim 1 , and 
 a printed decorative film bonded to an injection molded polymeric base structure; 
 wherein the coated thermoplastic film has been formed into a non-planar three-dimensional shape matching a three-dimensional shape of the injection molded polymeric base structure. 
 
     
     
       12. A method of molding an article, comprising:
 decorating and forming a coated thermoplastic film to form a shaped film, 
 wherein the coated thermoplastic film comprises a polymeric film substrate and a coating formed from a coating composition; and 
 wherein the coating composition comprises a urethane acrylate having a functionality of 2.0 to 6.0 acrylate functional groups, an acrylate monomer having a functional group, an epoxy acrylate oligomer having an acrylate functional group; and an additive comprising at least one of a silicone based additive, palmitic acid, and combinations comprising at least one of the foregoing; wherein the epoxy acrylate oligomer has one or more of an elongation percent at break of greater than or equal to 35%; a viscosity of less than or equal to 500 centipoise at 25° C.; a tensile strength of greater than or equal to 5 MegaPascals; a functionality of 1 to 6 functional groups; and a glass transition temperature of less than or equal to 25° C.; and 
 placing the shaped film into a mold, and injecting a resin into the mold cavity space behind the shaped film, wherein the shaped film and the injection molded resin form a single molded part. 
 
     
     
       13. The method of  claim 12 , further comprising
 printing a surface of the coated thermoplastic film opposite the coating with markings to obtain a decorative film; 
 forming and trimming the decorative film into a non-planar three-dimensional shape; 
 fitting the decorative film into the mold having a surface that matches the non-planar three-dimensional shape of the decorative film; and 
 injecting a resin comprising a polycarbonate resin into the mold cavity behind the decorative film to produce a one-piece, bonded non-planar three-dimensional product. 
 
     
     
       14. The method of any of  claim 12 , wherein the shaping the coated thermoplastic film comprises thermoforming. 
     
     
       15. The method of any of  claim 12 , further comprising curing the shaped film. 
     
     
       16. The method of any of  claim 12 , further comprising curing the product.